Reusable diapers

ABSTRACT

A reusable diaper may include an inner layer to wick moisture and an outer layer substantially impervious to liquids. A waist portion may include a corner region for securing the diaper in a desired position. The corner region may be resiliently stretchable and substantially impervious to liquids, and may include first and second layers coupled to the respective inner and outer layers. The coupled first layer and inner layer define a first seam allowance, and the coupled second layer and outer layer define a second seam allowance. The first and second seam allowances may be positioned within the corner region to help inhibit wicking of liquid through the seam allowances into the corner region. And a fluid-resistant region may be provided to help resist wicking of moisture through the inner layer past the fluid-resistant region.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/059,844 filed Mar. 31, 2008, which, in turn, is acontinuation-in-part of U.S. patent application Ser. No. 11/518,587filed Sep. 8, 2006 (now U.S. Pat. No. 7,629,501 issued Dec. 8, 2009),the entire disclosures of which are incorporated herein by reference.

FIELD

The present disclosure relates generally to reusable diapers.

BACKGROUND

The statements in this background section merely provide backgroundinformation related to the present disclosure and may not constituteprior art.

Absorbent articles, such as disposable diapers, training pants, orincontinence pads, generally have an absorbent core intended for singleuse only. Once the absorbent core component is saturated with bodilydischarges, such as urine, the entire absorbent article is usuallydiscarded. Oftentimes, parts of a disposable diaper or training pantscould be reused. But with the unitary construction, they arenevertheless discarded along with the saturated absorbent cores. Inaddition to the added cost and waste associated with discarding suchproducts, it is often inconvenient to acquire and store quantities ofsuch disposable absorbent articles.

SUMMARY

According to various aspects, exemplary embodiments are provided ofreusable diapers. In one exemplary embodiment, a reusable diapergenerally includes at least one inner layer configured to wick moistureand at least one outer layer configured to be substantially imperviousto liquids. A waist portion is generally defined by the at least oneinner layer and the at least one outer layer. The waist portion includesa corner region which can be used to secure the reusable diaper in adesired position. The corner region includes a first layer and a secondlayer which are coupled together to define an interior portion of thecorner region. The first layer is further coupled to the at least oneinner layer and the second layer is further coupled to the at least oneouter layer. The reusable diaper also includes a first seam allowancewhich is defined generally by the first layer of the corner region andthe at least one inner layer. The first seam allowance is positionedgenerally within the interior portion of the corner region and extendsgenerally away from the at least one inner layer. The reusable diaperalso includes a second seam allowance which is defined generally by thesecond layer of the corner region and the at least one outer layer. Thesecond seam allowance is positioned generally within the interiorportion of the corner region and extends generally away from the atleast one outer layer. The positioning of the first and second seamallowances generally helps to inhibit wicking of liquid through the seamallowances and into the corner region.

In another exemplary embodiment, a reusable diaper generally includes awaist portion having at least one resiliently stretchable corner regionfor use in securing the reusable diaper in a desired position. The atleast one resiliently stretchable corner region is substantiallyimpervious to liquids.

In another exemplary embodiment, a reusable diaper generally includes atleast one inner layer configured to wick moisture and at least one outerlayer configured to be substantially impervious to liquids. At least onepocket is defined generally by a space between the at least one innerlayer and the at least one outer layer. The at least one pocket isconfigured to receive at least one liquid-absorbent insert therein. Andthe at least one inner layer of the reusable diaper includes at leastone fluid-resistant region for resisting wicking of moisture past thefluid-resistant region.

In another exemplary embodiment, a reusable diaper generally includes atleast one inner layer configured to wick moisture and at least one outerlayer configured to be substantially impervious to liquids. At least onepocket is defined generally by a space between the at least one innerlayer and the at least one outer layer, and is configured to receive atleast one liquid-absorbent insert therein. A waist portion is generallydefined by the at least one inner layer and the at least one outerlayer. The waist portion includes at least one resiliently stretchablecorner region for use in securing the reusable diaper in a desiredposition. The resiliently stretchable corner region includes a firstlayer and a second layer coupled together so as to define an interiorportion of the corner region. The first layer is further coupled to theat least one inner layer, and the second layer is further coupled to theat least one outer layer. A first seam allowance is defined by the firstlayer of the corner region and the at least one inner layer. The firstseam allowance is positioned generally within the interior portion ofthe corner region and extends generally away from the at least onepocket. A second seam allowance is defined by the second layer of thecorner region and the at least one outer layer. The second seamallowance is positioned generally within the interior portion of thecorner region and extends generally away from the at least one pocket.The at least one inner layer includes at least one fluid-resistantregion for resisting wicking of moisture past the fluid-resistantregion. And the at least one resiliently stretchable corner region issubstantially impervious to liquids. Further, the positioning of thefirst and second seam allowances helps inhibit wicking of liquid fromthe at least one fluid-absorbent insert received within the at least onepocket through the seam allowances to the resiliently stretchable cornerregion.

Further aspects and features of the present disclosure will becomeapparent from the detailed description provided hereinafter. Inaddition, any one or more aspects of the present disclosure may beimplemented individually or in any combination with any one or more ofthe other aspects of the present disclosure. It should be understoodthat the detailed description and specific examples, while indicatingexemplary embodiments of the present disclosure, are intended forpurposes of illustration only and are not intended to limit the scope ofthe present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1 is an exploded perspective view of a reusable diaper having apocket opening and a flap according to exemplary embodiments, whereinthe flap is shown in an opened configuration in which the opening intothe pocket is exposed to allow a liquid-absorbent insert to bepositioned within the pocket;

FIG. 2 is a perspective view of the reusable diaper shown in FIG. 1,wherein the flap is shown in the closed configuration in which the flapsubstantially covers the opening into the pocket and inhibits contactbetween the diaper wearer and the liquid-absorbent insert positionedwithin the pocket;

FIG. 3 is a front perspective view of the reusable diaper shown in FIGS.1 and 2, wherein the top row of snap members have been snapped into thecorresponding snap members in the middle row thereby reducing thediaper's functional rise or crotch length;

FIG. 4 is an inner view of the reusable diaper shown in FIGS. 1 through3;

FIG. 5 is an inner view of the reusable diaper shown in FIG. 4, whereintabs have been releasably attached to the flap with hook-and-loopfasteners;

FIG. 6 is an outer view of the reusable diaper shown in FIGS. 1 through5;

FIG. 7 is an inner view of another exemplary embodiment of a reusablediaper;

FIG. 8 is an outer view of the reusable diaper of FIG. 7;

FIG. 9A is a fragmentary inner view of the reusable diaper of FIG. 7illustrating a first seam allowance formed when stitching a first layerof a corner region to a flap and an inner layer of the reusable diaper;

FIG. 9B is a view similar to FIG. 9A illustrating the first seamallowance stitched to the first layer of the corner region;

FIG. 9C is a section view taken in a plane including line 9C-9C in FIG.9B;

FIG. 10A is a fragmentary outer view of the reusable diaper of FIG. 7illustrating a second seam allowance formed when stitching a secondlayer of a corner region to an outer layer of the reusable diaper;

FIG. 10B is a view similar to FIG. 10A illustrating the second seamallowance stitched to the second layer of the corner region;

FIG. 10C is a section view taken in a plane including line 10C-10C inFIG. 10B;

FIG. 11 is a fragmentary view of a corner region of the reusable diaperof FIG. 7 illustrating an interior portion of the corner region withfirst and second seam allowances disposed generally within the interiorportion of the corner region; and

FIG. 12 is a section view taken in a plane including line 12-12 in FIG.11.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the present disclosure, application, or uses.

According to various aspects, exemplary embodiments are provided ofreusable diapers. In one exemplary embodiment, a reusable diapergenerally includes an inner layer configured to wick moisture from thediaper wearer's body and an outer layer configured to be substantiallyliquid-impervious. At least one pocket is defined generally by a spacebetween the inner and outer layers. The at least one pocket isconfigured to receive at least one liquid-absorbent insert therein. Thediaper also includes at least one slit in the inner layer that providesaccess into the space between the inner and outer layers defining the atleast one pocket. At least one flap is provided that is positionable inan open configuration or a closed position. When the at least one flapis in the open configuration, the at least one slit is exposed andallows access into the at least one pocket. In the closed configuration,however, the at least one flap substantially covers the at least oneslit and inhibits contact between the diaper wearer and at least oneliquid-absorbent insert positioned within the at least one pocket. Whenclosed, the at least one flap may also inhibit the inadvertent oraccidental removal of the at least one liquid-absorbent insert from theat least one pocket.

In another exemplary embodiment, a reusable diaper generally includesfirst and second waist portions. The first waist portion includes cornerregions that are releasably attachable to the second waist portion. Thecorner regions may be resiliently stretchable to permit at least someadjustability to the diaper's functional waist size as defined by thefirst and second waist portions when the first waist portion isreleasably attached to the second waist portion.

In another exemplary embodiment, a reusable diaper generally includes aforward portion, a rearward portion, and a crotch portion. The reusablediaper further includes at least a three-by-three array of snap membersalong the forward portion that allows selective adjustment to thediaper's functional rise or crotch length. The array includes at least afirst row of at least three spaced-apart snap members (e.g., plasticmale snap members, plastic female snap members, combinations thereof,etc.). The snaps in the first row are vertically spaced from and alignedwith corresponding snap members (e.g., plastic female snap members,plastic male snap members, combinations thereof, etc.) in at least twoother rows of the array. For example, snap members in a first or top rowcan be snapped together with the corresponding snap members in thesecond or middle row to decrease the diaper's functional rise or crotchlength. Or, for example, the snap members of the top row can be snappedtogether with the corresponding snap members in a third or bottom row toeven further decrease the diaper's functional rise or crotch length.Advantageously, having at least three columns of snaps may provide amore snug and precise fit to the diaper wearer, for example, by reducingthe extent to which the crotch portion hangs down below the wearer. Forexample, the three-by-three arrangement can eliminate or at least reducethe bulge in the middle front of the diaper that typically occurs whenthere are only two columns of snaps due to the fabric bulging outbetween the two snaps. The three-by-three snap arrangement may enablethe diaper to be more of a one-size fits all cloth diaper. Alternativeembodiments may include more or less than three rows of snaps, more orless than three columns of snaps, and/or different connector membersbesides snaps.

In some embodiments, a reusable diaper may include at least one innerliner or layer. The at least one inner layer can be configured to wickmoisture from the diaper wearer's body generally towards the at leastone liquid-absorbent insert within the at least one pocket. The reusablediaper may further comprise at least one outer layer or liner along atleast an outer portion of the reusable diaper. The at least one outerlayer can be substantially liquid-impervious to thereby resist wickingof moisture through the at least one outer layer. In some preferredembodiments, the outer layer is formed of polyester, and the inner layeris formed of suede cloth. Alternatively, other suitable materials may beused for the inner and/or outer layers.

In some embodiments, there may be provided a plurality of replacementliquid-absorbent inserts. In such embodiments, an existingliquid-absorbent insert may be removed from a pocket after the inserthas become saturated. One of the replacement inserts can be positionedwithin the pocket after the diaper has been washed or laundered.

Other embodiments of a reusable diaper may include a first waist portionhaving corner regions with tabs releasably attachable to a second waistportion. The corner regions may be resiliently stretchable to permitsome adjustability to the functional waist size of the reusable diaperas defined by the first and second waist portions. In some embodiments,the corner regions may be formed from 95% polyester and 5% Lycra.Alternatively, the corner regions may be formed using other suitablematerials. The tabs may also be releasably attachable to an interiorportion of the diaper (e.g., to a back side of a flap, etc.) forretaining the corner regions and tabs within the interior of thereusable diaper. A wide range of attachment means may be used forreleasably attaching the tabs to the second waist region and/or to aninterior portion of the diaper, such as hook-and-loop fasteners, snaps,buttons, adhesives, combinations thereof, etc.

Referring now to FIGS. 1 through 6, there is shown an exemplaryembodiment of a reusable diaper 100 embodying one or more aspects of thepresent disclosure. As shown, the reusable diaper 100 includes a firstwaist portion or region 110, a second waist portion or region 112, and acrotch portion or region 114 disposed generally between the first andsecond waist portions 110, 112. The first waist portion 110 includescorner regions 116 and 118. The second waist portion 112 includes cornerregions 120 and 122.

As shown in FIG. 2, the contours of the corner regions 116, 118, 120,122 and crotch portion 114 cooperatively define leg openings 124 and126. For example, leg opening 124 is cooperatively defined by the curveextending from the first waist portion's corner region 116 along thecrotch portion 114 to the second waist portion's corner region 120. Inaddition, the other leg opening 126 is defined by the curve extendingfrom the first waist portion's corner region 118 along the crotchportion 114 to the second waist portion's corner region 122. In thisillustrated embodiment, the leg openings 124 and 126 may furthercomprise elastic disposed adjacent the periphery of the leg openings 124and 126, for example, to help draw and hold the diaper 100 against thewearer's legs.

With continued reference to FIG. 1, the reusable diaper 100 includes apocket 102 defined generally by the space between the diaper's outerlayer 158 and inner layer 160. The diaper 100 also includes an openingor slit 104 in the inner layer 160 that allows access into the pocket102. The reusable diaper 100 further includes a flap 108 positionable ineither an open configuration (FIGS. 1 and 4) or a closed configuration(FIGS. 2 and 5).

When the flap 108 is in the open configuration, the slit 104 is exposedand allows access into the pocket 102. In the closed configuration,however, the flap 108 substantially covers the slit 104 and inhibitscontact between the skin or clothes of the diaper wearer and theliquid-absorbent insert 106 positioned within the pocket 102.Additionally, closing the flap 108 may also inhibit the inadvertent oraccidental removal of the insert 106 from the pocket 102. In alternativeembodiments, a suitable attachment means may be employed for releasablyretaining the flap in the closed position, such as hook-and-loopfasteners, snaps, adhesives, buttons, clasps, magnets, combinationsthereof, etc.

The flap 108 may be formed from a wide variety of materials. In somepreferred embodiments, the flap 108 is formed from one or more fabricmaterials, such as suede cloth, etc. In such embodiments, the flap 108and the inner layer 160 may be formed from the same materials.Alternatively, the flap 108 and inner layer 160 may be formed fromdifferent materials.

The flap 108 may be attached to the reusable diaper 100 using a widevariety of attachment methods, such as stitching, sewing, adhesiveattachment, integrally formed, etc. In some preferred embodiments, theflap 108 is attached to the inner layer 160 along the diaper's rearportion by stitching or sewing. In such embodiments, the flap 108 andopening 104 into the pocket 102 are not readily accessible by the diaperwearer.

As shown in FIG. 1, a liquid-absorbent insert 106 can be received withinthe pocket 102 via the slit 104. The insert 106 is preferably configuredto absorb and store liquids therein. The insert 106 may comprise one ormore of microfibers, hemp, hydrocolloid materials, or any other suitablematerial configured to absorb and store liquids therein.

In this particular embodiment, the insert 106 is shown with snap members107 and 109. These snap members 107, 109 can be snapped together orunsnapped to thereby allow selective adjustment to the length of theinsert 106. For example, the snap member 107 can be snapped togetherwith the snap member 109 to decrease the insert's length. Or, forexample, the snap members 107 and 109 can be unsnapped to increase theinsert's length. This lengthwise adjustability can allow the insert 106to more precisely fit within the pocket 102, for example, when thefunctional rise or crotch length of the diaper is changed by way of thearray of snaps 180 (as described in more detail below). Alternativeembodiments may include an insert having more or less snaps and/or snapsin other arrangements to accommodate lengthwise adjustability to theinsert. Further embodiments may include an insert having a wide range ofother suitable fastening systems besides snaps, such as adhesives,buttons, clasps, Velcro® hook and loop closures, magnets, elasticstraps, adjustable straps, combinations thereof, etc.

In the illustrated embodiment, the pocket 104 is defined generally bythe space between the diaper's outer layer 158 and inner layer 160. Thepocket's periphery or perimeter is defined to extend generally fromabout the first waist portion 110 along the first and second edgeportions 154, 156 of the crotch region 114 to about the second waistportion 112. Stitching (or other suitable means) may be used to securethe perimeter or periphery of the pocket 102. For example, theillustrated embodiment has the pocket periphery formed generally by thesame stitching used to attach the outer and inner layers 160, 158 toeach other.

A wide range of suitable materials may be used for the inner and outerlayers 160, 158. The inner layer 160 is preferably configured to wickmoisture generally away from the diaper wearer towards the insert 106within the pocket 102. The outer layer 158 is preferably configured tobe substantially liquid-impervious to thereby resist wicking of moisturethrough the outer layer 158. In one preferred embodiment, the outerlayer 158 is formed of polyester, and the inner layer 160 is formed ofsuede cloth. Alternatively, other suitable materials may be used for theinner liner and/or outer layers 160, 158.

Accordingly, the reusable diaper 100 may be put on a wearer with theinner layer 160 positioned against the skin of the wearer. In whichcase, the inner layer 160 can wick moisture (e.g., bodily discharge,urine, sweat, etc.) through the inner layer 160 to the liquid-absorbentinsert 106 within the pocket 102. When the insert 106 has becomesaturated, the insert 106 may be removed and then washed or launderedalong with or separately from the diaper 100. After the diaper 100 andinsert 106 have been satisfactorily washed and dried, the insert 106 maybe repositioned within the pocket 102 of the diaper 100. At which point,the diaper 100 may be reused.

In some preferred embodiments, the first waist portion's corner regions116 and 118 are resiliently stretchable. This feature allows at leastsome adjustability to the diaper's functional waist size as defined bythe first and second waist portions 110 and 112 when the first waistportion 110 is releasably attached to the second waist portion 112. Insome embodiments, the corner regions may be formed from 95% polyesterand 5% Lycra. Alternatively, the corner regions may be formed usingother suitable materials.

With reference to FIG. 2, the reusable diaper 100 includes tabs 130, 132associated with the first waist portion 110. In addition to stretchablecorner regions, some embodiments also configure the tabs 130, 132 to beresiliently elastic or stretchable. This, in turn, can permit furtheradjustability to the diaper's functional waist size. In yet otherembodiments, only the tabs 130 and 132 are resiliently elastic orstretchable. In further embodiments, however, the tabs 130, 132 may beessentially inelastic or stretchable.

The tabs 130, 132 may include respective hook-and-loop fastener portions144, 146, which, in turn, are releasably attachable to correspondinghook-and-loop fastener portions of the second waist portion 112. Asshown in FIG. 2, the second waist portion 112 includes an elongate strip134 having hook-and-loop fastener portions extending along the lengththereof. Accordingly, the hook-and-loop fastener portions 144, 146 ofthe tabs 130, 132, respectively, can be releasably attachable atdifferent locations along the elongate strip 134, which allows the firstwaist portion 110 to be adjustably secured to the second waist portion112 when positioned around a wearer of the reusable diaper 100.

Having resiliently elastic or stretchable corner regions 116, 118(and/or tabs 130, 132 in some embodiments) with the ability to stretchcan allow for tailoring of the diaper's functional waist size to thewearer's actual waist size. For example, the diaper's functional waistsize may be selectively tailored for the wearer by stretching the cornerregions 116, 118, and then releasably attaching the tabs 130, 132 to theelongate strip 134 at particular attachment locations along the lengthof the elongate strip 134. In this exemplary manner, the diaper'sfunctional waist size can be selectively adjusted, for example, toprovide a relatively snug fit about the waist of the wearer (e.g.,infant, toddler, adult, etc.), and preferably without being toouncomfortably tight about the wearer's thighs. Alternative embodimentsmay include other suitable means for allowing selective adjustment tothe functional or operational waist size of the reusable diaper. Inaddition, other suitable fastening systems may also be employed forreleasably attaching the diaper's first and second waist portions toeach other, such as different hook-and-loop fastener arrangements (e.g.,two or more spaced-apart discrete patches along the second waist portioninstead of a single elongate strip, etc.), adhesives, snaps, buttons,clasps, Velcro® hook and loop closures, magnets, combinations thereof,etc.

In some embodiments, the tabs 130, 132 may be releasably attachable toan interior portion of the diaper for retaining the corner regions andtabs within the interior of the reusable diaper. As shown in FIG. 2, thetabs 130, 132 include hook-and-loop fastener portions 144, 146releasably attachable to corresponding hook-and-loop fastener portions178 of the flap 108. Releasably attaching the tabs 130 and 132 to theflap 108 by way of the hook-and-loop fastener portions 144, 146, 178(FIG. 5) helps retain the tabs 130 and 132 and corner regions 116 and118 within an interior of the diaper 100. This, in turn, may help toprevent or at least reduce snagging of the tabs 130, 132 when thereusable diaper 100 is being washed or laundered. Alternatively, a widerange of other attachment means may be used for releasably attaching thetabs 130, 132 to an interior portion of the diaper, such ashook-and-loop fasteners, snaps, buttons, adhesives, combinationsthereof, etc.

In some embodiments, the tabs 130, 132 may be releasably attachable toeach other. For example, one of the tabs 130 or 132 may have a forwardsurface with hook-and-loop fasteners that are releasably attachable tohook-and-look fasteners on a rearward surface of the other tab 130 or132. Alternatively, other suitable fastening means can be employed toimplement this feature.

With reference to FIG. 6, the reusable diaper 100 includes snaps thatallow for customization or adjustment to the diaper's functional rise orcrotch length. This feature may help create an even better or snuggerfit to the diaper wearer. For example, the snaps can allow for areduction in the diaper's functional rise or crotch length so as toreduce the extent to which the crotch portion 114 hangs down below thewearer.

As shown in FIG. 6, the diaper 100 includes a three-by-three array 180of snap members. The snap members comprising the three-by-three array180 are horizontally arranged and aligned in the three rows andvertically arranged and aligned in the three columns. Advantageously,having at least three columns may provide a more snug and precise fit tothe diaper wearer, for example, by reducing the extent to which thecrotch portion hangs down below the wearer. The three-by-threearrangement can eliminate or at least reduce the bulge in the middlefront of the diaper that typically occurs when there are only twocolumns of snaps due to the fabric bulging out between the two snaps.The three-by-three snap arrangement may enable the diaper to be more ofa one-size fits all cloth diaper.

In the illustrated embodiment, the first row includes three spaced-apartmale snap members 182. The second or middle row includes threespaced-apart female snap members 184. The third row includesthree-spaced apart female snap members 186. The male snap members 182can be snapped together with either the female snap members 184 of thesecond row, or the female snap members 186 of the third row. Forexample, the male snap members 182 in the first row can be snappedtogether with the corresponding female snap members 184 in the second ormiddle row to decrease the diaper's functional rise or crotch length. Todecrease the diaper's functional rise and crotch length to an evengreater extent, the male snap members 182 of the first row may insteadbe snapped together with the corresponding female snap members 186 inthe third row. Accordingly, these snap options thus provide threedifferent configurations for the diaper 100. That is, the functionalrise or crotch length of the reusable diaper 100 can be changed byselectively choosing whether to engage the male snap members 182 withthe female snap members 184 or the female snap members 184, or by simplychoosing to do neither.

In some preferred embodiments, the snap members 182, 184, 186 areplastic. Alternatively, the snap members can be formed from othermaterials, which are preferably relatively lightweight and durable towithstand repeated laundry cycles.

In alternative embodiments, a reusable diaper may include more or lesssnap options and/or snap members in other arrangements than what isshown in FIG. 6. For example, another embodiment may include two rows ofmale snap members with only one row of female snap members. As anotherexample embodiment, a diaper may include a row having both male andfemale snap members. Additional examples include diapers having more orless than three rows of snap members and/or more or less than threecolumns of snap members. Still further embodiments may include a widerange of other suitable fastening systems besides snaps, such asadhesives, buttons, clasps, Velcro® hook and loop closures, magnets,elastic straps, adjustable straps, combinations thereof, etc.

In some embodiments, a reusable diaper may also include a foldable frontportion along the second waist portion. This foldable front portion maybe folded down, for example, to help keep the umbilical area of thediaper wearer clean.

Other aspects of the present disclosure relate to methods. In oneexemplary embodiment, a method generally includes positioning at leastone liquid-absorbent insert through at least one slit or opening into atleast one pocket of a reusable diaper. The method may further includeclosing at least one flap to substantially cover the at least one slitor opening, whereby the at least one flap inhibits contact between thediaper wearer and the at least one liquid-absorbent insert and/orinhibits the inadvertent removal of the at least one liquid-absorbentinsert from the at least one pocket.

In some embodiments, the method may include opening the at least oneflap to thereby expose the at least one slit or opening and allow accessto the at least one pocket. The method may include removing at least oneliquid-absorbent insert from the at least one pocket out through the atleast one slit or opening. After laundering or washing the diaper, atleast one replacement liquid-absorbent insert may be positioned throughthe at least one slit into the at least one pocket. As another example,a method may include removing the reusable diaper from a wearer beforeopening the at least one flap, removing the at least oneliquid-absorbent insert, washing or laundering the diaper and theliquid-absorbent insert, and positioning the liquid-absorbent insertwithin the pocket.

In some embodiments, a method may further comprise selectively adjustinga functional waist size of the reusable diaper to a wearer, bystretching corner regions of a first waist portion of the reusablediaper, and then releasably attaching tabs associated with the cornerregions to a second waist portion of the reusable diaper. In somepreferred embodiments, the tabs may be releasably attached to the secondwaist portion by using hook-and-loop fasteners. Additional embodiments,however, may alternatively comprise snaps, buttons, adhesives, magnets,combinations thereof, etc.

FIGS. 7-12 illustrate another exemplary embodiment of a reusable diaper(indicated generally at 200) embodying one or more aspects of thepresent disclosure. As shown in FIGS. 7 and 8, the reusable diaper 200generally includes a first waist portion 210 (e.g., a rearward waistportion, etc.), a second waist portion 212 (e.g., a forward waistportion, etc.), and a crotch portion or region 214 disposed generallybetween the first and second waist portions 210, 212. The first waistportion 210 includes corner regions 216, 218 which are releasablyattachable to the second waist portion 212 to secure the reusable diaper200 in a desired position. More particularly, tabs 230, 232 of therespective corner regions 216, 218 are releasably attachable (e.g., viacorresponding hook-and-loop fasteners, etc.) to an elongate strip 234 ofthe second waist portion 212 (FIG. 8) to secure the diaper in a desiredposition (e.g., around a wearer, with the wearer generally in contactwith an inner layer 260 of the reusable diaper 200, etc.).

The corner regions 216, 218 of the first waist portion 210 may beresiliently stretchable. This feature allows for at least someadjustability of the diaper's functional waist size as defined by thefirst and second waist portions 210, 212 when the first waist portion210 is releasably attached to the second waist portion 212. Moreover,the resiliently stretchable corner regions 216, 218 may be substantiallyimpervious to fluids. For example, the resiliently stretchable cornerregions 216, 218 may be at least partially coated, treated, etc. withdurable water repellant to make them substantially impervious toliquids. Any suitable durable water repellant may be used within thescope of the present disclosure. In other exemplary embodiments,reusable diapers may include resiliently stretchable corner regionshaving other suitable materials, coatings, etc. applied thereto to makethe resiliently stretchable corner regions substantially impervious toliquids.

With continued reference to FIGS. 7 and 8, the reusable diaper 200 alsoincludes an outer layer 258 and the inner layer 260. The outer layer 258and the inner layer 260 may broadly be viewed as defining at least partof the first and second waist portions 210, 212. The outer layer 258 maybe configured to be substantially liquid-impervious to thereby resistwicking of moisture through the outer layer 258, and may be formed, forexample, of polyester, nylon, spandex, combinations thereof, etc. Theinner layer 260 may be configured to wick moisture generally away, forexample, from a diaper wearer, and may be formed, for example, of suedecloth, polyester suede cloth, micro fleece, other forms of fabricdesigned to wick moisture, combinations thereof, etc. A pocket 202 isdefined generally by the space between the diaper's outer layer 258 andinner layer 260. The pocket 202 is configured (e.g., sized, shaped,constructed, etc.) to receive at least one liquid-absorbent insert 206therein, for example, for help in absorbing and storing liquids (e.g.,moisture wicked away from a diaper wearer, etc.). An opening or slit 204is formed in the inner layer 260 to allow access into the pocket 202,and a flap 208 coupled generally to the first waist portion 210 can bepositioned to cover the slit 204 and help retain the liquid-absorbentinsert 206 within the pocket 202 as desired.

The reusable diaper 200 may further include one or more fluid-resistantregions that, for example, may help resist wicking of moisture throughthe diaper 200 past the one or more fluid-resistant regions. In theillustrated reusable diaper 200, the inner layer 260 includes afluid-resistant region disposed adjacent the second waist portion 212.More particularly in the illustrated reusable diaper 200, and as bestshown in FIG. 7, the fluid-resistant region includes a strip 288 coupled(e.g., seamed, stitched, etc.) to both the inner layer 260 and the outerlayer 258. Here, the fluid-resistant strip 288 may be viewed as definingat least part of the first waist portion 212. The fluid-resistant strip288 extends generally across a width of the inner layer 260substantially from one corner region 220 of the second waist portion 212to another corner region 222 of the second waist portion 212. This maysubstantially resist wicking of moisture through the inner layer 260past the fluid-resistant strip 288. It should be appreciated that a widerange of suitable materials, coatings, laminates, etc. may be used forthe fluid-resistant strip 288, including, for example, polyestermaterials, durable water repellant coatings, etc.

As previously stated, the one or more fluid-resistant regions (e.g., thefluid-resistant strip 288, etc.) of the illustrated reusable diaper 200may help resist wicking of moisture through the diaper 200 past the oneor more fluid-resistant regions. In the illustrated embodiment, forexample, the fluid-resistant strip 288 is disposed adjacent the secondwaist portion 212 and may help prevent wicking of moisture from thereusable diaper 200 (e.g., from the liquid-absorbent insert 206 receivedwithin the pocket 202 of the reusable diaper 200, from the inner layer260 of the reusable diaper 200, etc.) to a shirt, blanket, article ofbedding, etc. that may come into contact with a part of the first waistportion 212 (e.g., an inner part of the first waist portion 212, etc.).In other exemplary embodiments, reusable diapers may include innerlayers having fluid-resistant regions shaped differently than disclosedherein; having fluid-resistant regions disposed, located, etc.differently than disclosed herein; having fluid-resistant regions withone or more separated parts; etc. For example, in one exemplaryembodiment, fluid-resistant regions may be disposed adjacent one or moreof waist portions, leg regions, etc. of reusable diapers. In oneexemplary embodiment, fluid-resistant regions are disposed adjacent bothfirst and second waist portions of a reusable diaper.

With additional reference now to FIGS. 9-12, the resiliently stretchablecorner regions 216, 218 of the first waist portion 210 of the reusablediaper 200 will be described. FIGS. 9-12 illustrate the resilientlystretchable corner region 216, with it understood that a description ofthe resiliently stretchable corner region 218 would be substantially thesame (similar reference numbers are thus used in the figures forcorresponding parts of the resiliently stretchable corner regions 216,218). As shown, the resiliently stretchable corner region 216 includes afirst layer 290 and a second layer 291, which are coupled together todefine an interior region/portion 292 (FIGS. 11 and 12) of the cornerregion 216. In the illustrated embodiment, the first layer 290 and thesecond layer 291 are coupled via stitches. Alternatively, other suitablemethods, materials, etc. may be used to couple the first and secondlayers 290, 291 together to define the interior portion 292 (e.g.,epoxy, hot-melt processes, etc.).

As best shown in FIGS. 7 and 9A-9C, the first layer 290 of theillustrated corner region 216 is also coupled to the flap 208 and theinner layer 260 of the reusable diaper 200. To do so, edge margins ofthe first layer 290, the flap 208, and the inner layer 260 may first begenerally aligned such that the first layer 290, the flap 208, and theinner layer 260 are in a generally overlapped position (FIG. 9A). Astitch 293 may then be positioned through the first layer 290, the flap208, and the inner layer 260 adjacent their generally aligned edgemargins to couple them together. This defines a first seam allowance 294between the stitch 293 and the edge margins of the first layer 290, theflap 208, and the inner layer 260. The first layer 290 may then befolded at the stitch 293 so as to overlap the first seam allowance 294.And a top-stitch 295 may then be positioned through the folded firstlayer 290 and the first seam allowance 294 (FIGS. 9B and 9C) to couplethe first seam allowance 294 to the first layer 290.

As best shown in FIGS. 8 and 10A-10C, the second layer 291 of the cornerregion 216 is also coupled to the outer layer 258 of the reusable diaper200. To do so, edge margins of the second layer 291 and the outer layer258 may first be generally aligned such that the second layer 291 andthe outer layer 258 are in a generally overlapped position (FIG. 10A). Astitch 296 may then be positioned through the second layer 291 and theouter layer 258 adjacent their generally aligned edge margins to couplethem together. This defines a second seam allowance 297 between thestitch 296 and the edge margins of the second layer 291 and the outerlayer 258. The second layer 291 may then be folded at the stitch 296 soas to overlap the second seam allowance 297. And a top-stitch 298 maythen be positioned through the folded second layer 291 and the secondseam allowance 297 (FIGS. 10B and 10C) to couple the second seamallowance 297 to the second layer 291.

It should be appreciated that at least part of the flap 208, the innerlayer 260, and the outer layer 258 may be coupled together before thefirst and second layers 290, 291 of the corner region 216 are coupledthereto. Alternatively, the first and second layers 290, 291 of thecorner region 216 may be coupled to the respective flap 208, inner layer260, and outer layer 258 of the reusable diaper 200 before the flap 208,inner layer 260, and outer layer 258 are coupled together within thescope of the present disclosure. In addition in other exemplaryembodiments, three or more stitches may be used to couple first andsecond layers of corner regions to respective flaps, inner layers, andouter layers of reusable diapers. In still other exemplary embodiments,reusable diapers may have corner regions coupled thereto other than bystitching (e.g., by epoxy, by hot-melt processes, etc.).

With particular reference now to FIGS. 11 and 12, the first and secondseam allowances 294, 297 (when coupled to the respective first andsecond layers 290, 291 of the corner region 216) are positionedgenerally within the interior portion 292 of the corner region 216. Inthis position, the first and second seam allowances 294, 297 each extendgenerally away from the respective outer layer 258 and inner layer 260of the reusable diaper 200 (and away from the pocket 202 formed betweenthe outer layer 258 and the inner layer 260). This may help inhibitwicking of liquid through the first and second seam allowances 294, 297to the corner region 216. For example, in the illustrated reusablediaper 200, moisture moving through the reusable diaper 200 (e.g.,through the liquid-absorbent insert 206 received within the pocket 202formed between the outer and inner layers 258, 260; through the innerlayer 260; along the substantially liquid-impervious outer layer 258;etc.) may approach the corner region 216 (as well as the corner region218) of the first waist portion 210. But the positioning of the firstand second seam allowances 294, 297 generally facing away from themoisture transporting regions of the reusable diaper 200 (e.g., theliquid-absorbent insert 206; the inner layer 260; along thesubstantially liquid-impervious outer layer 258; etc.) may help inhibitthe moisture approaching the corner region 216 (as well as the cornerregion 218) from actually entering and thus wetting the corner region216. The moisture may not substantially move into contact with the firstand/or second seam allowances 294, 297 and thus may not enter the cornerregions 216 and/or 218. Thus, the first and second seam allowances 294,297 are uniquely positioned generally away from the moisture regions ofthe reusable diaper 200 so as to help inhibit wicking of liquid into thecorner regions 216, 218.

Certain terminology is used herein for purposes of reference only, andthus is not intended to be limiting. For example, terms such as “upper”,“lower”, “above”, and “below” refer to directions in the drawings towhich reference is made. Terms such as “front”, “back”, “rear”,“bottom,” “side”, “inner,” “outer,” etc. describe the orientation ofportions of the component within a consistent but arbitrary frame ofreference which is made clear by reference to the text and theassociated drawings describing the component under discussion. Suchterminology may include the words specifically mentioned above,derivatives thereof, and words of similar import. Similarly, the terms“first”, “second” and other such numerical terms referring to structuresdo not imply a sequence or order unless clearly indicated by thecontext.

When introducing elements or features and the exemplary embodiments, thearticles “a”, “an”, “the” and “said” are intended to mean that there areone or more of such elements or features. The terms “comprising”,“including” and “having” are intended to be inclusive and mean thatthere may be additional elements or features other than thosespecifically noted. It is further to be understood that the methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder or performance. It is also to be understood that additional oralternative steps may be employed.

The description of the disclosure is merely exemplary in nature and,thus, variations that do not depart from the gist of the disclosure areintended to be within the scope of the disclosure. Such variations arenot to be regarded as a departure from the spirit and scope of thedisclosure.

1. A reusable diaper comprising: a waist portion having at least oneresiliently stretchable corner region for use in securing the reusablediaper in a desired position; wherein the at least one resilientlystretchable corner region is substantially impervious to liquids.
 2. Thereusable diaper of claim 1, wherein the at least one resilientlystretchable corner region is at least partially coated with durablewater repellent such that the at least one resiliently stretchablecorner region is substantially impervious to liquids.
 3. The reusablediaper of claim 2, wherein the at least one resiliently stretchablecorner region includes at least one tab releasably attachable to thereusable diaper for use in securing the reusable diaper in a desiredposition.
 4. The reusable diaper of claim 3, wherein the waist portionincludes two resiliently stretchable corner regions for use in securingthe reusable diaper in a desired position, the two resilientlystretchable corner regions each being at least partially coated withdurable water repellent such that the two resiliently stretchable cornerregions are substantially impervious to liquids.
 5. The reusable diaperof claim 4, wherein the waist portion is a first waist portion, thereusable diaper further comprising: a second waist portion; the tworesiliently stretchable corner regions of the first waist portion beingreleasably attachable to the second waist portion to secure the reusablediaper in a desired position, the resiliently stretchable corner regionspermitting at least some adjustability to the functional waist size ofthe reusable diaper as defined by the first and second waist portionswhen the first waist portion is releasably attached to the second waistportion.
 6. The reusable diaper of claim 2, further comprising: at leastone inner layer configured to wick moisture; at least one outer layerconfigured to be substantially impervious to liquids; at least onepocket defined generally by a space between the at least one inner layerand the at least one outer layer, and configured to receive at least oneliquid-absorbent insert therein.
 7. A reusable diaper comprising: atleast one inner layer configured to wick moisture; at least one outerlayer configured to be substantially impervious to liquids; at least onepocket defined generally by a space between the at least one inner layerand the at least one outer layer, and configured to receive at least oneliquid-absorbent insert therein; and wherein the at least one innerlayer includes at least one fluid-resistant region for resisting wickingof moisture past the at least one fluid-resistant region.
 8. Thereusable diaper of claim 7, further comprising a waist portion generallydefined by the at least one inner layer and the at least one outerlayer, the at least one fluid-resistant region being disposed adjacentthe waist portion.
 9. The reusable diaper of claim 8, wherein the atleast one fluid-resistant region includes a fluid-resistant stripextending generally across a width of the at least one inner layer. 10.The reusable diaper of claim 9, wherein the fluid-resistant strip andthe at least one outer layer are coupled together to generally define atleast part of the waist portion.
 11. The reusable diaper of claim 7,further comprising: a first waist portion having two corner regions; asecond waist portion, the at least one fluid-resistant region beingdisposed adjacent the second waist portion; the two corner regions ofthe first waist portion being releasably attachable to the second waistportion to secure the reusable diaper in a desired position, the twocorner regions each being resiliently stretchable to permit at leastsome adjustability to the functional waist size of the reusable diaperas defined by the first and second waist portions when the first waistportion is releasably attached to the second waist portion.